Wing Tip Lenses

I had this idea that I would conceal the lighting in the wing tip and make a lense to cover them. However, it turned out to be a huge job. Since I made the custom wing tip shapes, I had to mold my own acrylic lenses. Initially, I thought I could simply pull hot plexiglass over the finished wing tip. Wrong. The plexi wouldn't conform to the complex curve. Finally, I found the right person in Edmonton (Acro Foam) to vacuum form the plexi. However, he required a solid male mold to stretch the plexiglass over. Wow, what a job. Below are pictures of the various stages.

This is the "rock" male mold for both left and right wing tips. 

This is the roughed out notch where the wing tip light will go.

 I fiberglass the opening to seal everything off.

 Trial fit the lense I cut out.

Nearly finished. I'll do a little more tweaking and cleaning it up. It's 90% done. 
I still need to mount the strobe and the lights. That will be done after the airplane is painted.

This was taken yesterday.